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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKV-A5 Golf/Jettas

VW MKV-A5 Golf/Jettas Discussions area for A5/MkV Jetta/Golf (2005/2006 PD and 2009 CR).

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Old September 12th, 2011, 21:52   #61
BrokenTDI
Veteran Member
 
Join Date: Sep 2011
Location: Chilliwack B.C. Canada
Default Canadian HPFP failure

Year:2010
Build Date: ???
Make/Model: Golf TDI
Tranny: DSG, 6M 6M
Mileage: (actual miles at time of problem or when problem began) 132000 kms
Diesel Fuel Source: (Shell, Exxon, etc.) Petro Canada
Additives: (Yes/No) No
Problem: (HPFP failed, fuel canister rusted, etc. Give as much factual data as you can.) Driving along and had flashing glowplug light. Car went into "limp" mode for 10k then stalled on the hiway, Attepmts to restart were unsucsessful. Towed to dealer where after two days it was diagnosed with complete contamination of the fuel system from metal shards from HPFP destruction. Because it is out of warranty my battle with VW Canada will be an uphill one.
Dealer: Towed to Valley Autohouse Abbotsford B.C. Canada
Status: (still pending, dealer fixed everything, resolved, dealer refused, paid out of pocket)Pending
Costs of repairs to be covered by VWofCanada. I have been quoted a "minimum of $7000 for the repair.I am in the "wait and see mode" I am prepared to get a lawyer when the time comes. Nobody should have to be held hostage by a car manufacturer.

Last edited by BrokenTDI; September 12th, 2011 at 21:56. Reason: Wrong information
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Old September 16th, 2011, 11:26   #62
TDI117
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Join Date: Sep 2011
Location: Chattanooga, TN
Default

Year: 2012
Build Date:
?
Make/Model: Golf TDI
Tranny: DSG
Mileage: 1750
Diesel Fuel Source: BP
Additives: NO
Problem: Car became hard to start and seemed sluggesh under acceleration. Dealer reported they could not duplicate the problem the first time they had the car. When I took the car back to them the second time the next day they kept the car and reported back "contaminated fuel
Dealer: Village VW of Chattanooga
Status: Dealer fixing the car under warranty loaner car given (Piece of S*.T) waiting to get it fixed.
Cost: No cost to me. Dealer paying for rental.

Last edited by TDI117; September 16th, 2011 at 13:42.
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Old September 20th, 2011, 18:28   #63
Batgo
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Join Date: Sep 2011
Location: Ft Lauderdale
TDI(s): 2009 Jetta
Default

Year: 2009
Build date: 08-08
Make/Model:Jetta TDI
Tranny: DSG
Mileage: 20500
Diesel Fuel Source: Hess
Additives: None
Problem: Flashing glowplug light and loss of power 70 mph. Drove off exit ramp in limp mode. Car died at stop light and would not start. Towed to dealer. Dealer found fuel contaminated with metal particles. HPFP failure.
Dealer: Vista VW, Pompano Beach, Florida.
Status: Dealer replacing entire fuel system no charge. Some parts on back order. Free 2011 Jetta loaner. Friendly, no hassle service. VW wants fuel tested. Update, car repaired after 10 days at dealer.

Last edited by Batgo; September 26th, 2011 at 17:58.
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Old September 26th, 2011, 17:31   #64
pcnorton
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Join Date: Jan 2011
Location: Indian Orchard MA
TDI(s): 2011 JSW
Default

Year:2011
Build Date:?
Make/Model:VW JSW
Tranny: DSG,
Mileage: 25K
Diesel Fuel Source: Pride
Additives: No
Problem: Car stalled after glow plug light then check engine. Dealer initial report: Contaminated fuel
Dealer: Northampton VW
Status: Dealer covering but not being worked on yet
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Old October 14th, 2011, 20:39   #65
turborod
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Join Date: Sep 2011
Location: SoCal
Fuel Economy: maybe 40-41 if I slow down
Default

Year; 2009
Build date; 7/11/08
Tranny; DSG 6
Mileage; 105,357
Diesel fuel source; Usually Arco..last season letting it run very low before refueling.
Additives; Nah
Problem; Great driver then flashing glow plug light, reset by turning off, then into limp mode again, side streets 20 miles home. Wouldn't start the next AM and is flatbedded to the dealer.
Dealer; Ontario VW (SoCal not Canada)
Status; In 9/6/11 returned 10/12/11. Cause "HPFP internally destroyed contaminating fuel system", " Inspected vehicle and found not startingjust cranks. scanned with guided fault fing and found fault p0087 fuel rail pressure to (sic) low multiple times. remove fuel filter and metering valve on high pressure pump and found metal shavings inside high pressure pump and in fuel filter. opened vta ticket # 794153 and sent photos and information of problem. was advised by tech line that fuel system has been contaminated and needs replacing and fuel sample needs to be sent to lab for processing. sent fuel line sample and as per tech line removed fuel tank with pump and fuel lines and install new injectors with seals and new fuel lines on motor. install around 5 gallons of new fuel and primed system and bleed using gff test plan. let idle and test drove with no isuues on test drive and no leaks found after test drive"
Machatronic unit is updated as well.
I had a 100K extended mile warranty. Told me VWA covered it and not the warranty. Furnished me a new Passat but had power steering and battery issues and used a new gas Jetta for the other 5 weeks. Hope I have the newest updated updated updated HPFP version so I can hit 350k !!
VW Ontario Ca. have been very accomodating. Have only a few more payments left.
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Old October 16th, 2011, 23:26   #66
SandDiesel
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Join Date: Oct 2008
Location: AZ
TDI(s): 2009
Default

Year: 2009
Build Date: unk
Make/Model: Jetta TDI
Tranny: DSG
Mileage: 50K
Diesel Fuel Source: Chevron 90%
Additives: No
Problem: HPFP failed. Saw shavings in pump.
Dealer:
Status: Good will warranty covered it, but traded car on the spot.
__________________
2012 Jetta TDI
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Old October 17th, 2011, 17:47   #67
kndonlee
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Join Date: Dec 2010
Location: 18104
Default

Year: 2010
Build Date: ?
Make/Model: Audi A3 TDI
Tranny: DSG
Mileage: 50,200
Diesel Fuel Source: Majority Interstate Sunoco, random other places
Additives: No
Problem: HPFP Failure it seems: Coils & Battery (glowplug & alternator) warning light blinking followed by loss of power and no start of car.
Dealer: Purchased @ Don Rosen Audi in Conshohocken, PA. Attempting fix in Duncan Audi in Roanoke, VA
Status: Awaiting dealer diagnosis
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Old October 21st, 2011, 16:41   #68
speedeep
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Join Date: Dec 2010
Location: Prattville, AL
Default 2011 CJAA Jetta TDI - HPFP Failure @ 13.4k miles

Year: 2011
Build Date: 4/2011 (Purchased 5/28/2011)
Make/Model: Jetta TDI
Tranny: DSG
Mileage: ~13,413
Diesel Fuel Source: majority Shell, BP, Exxon. Detailed fuel records kept.
Additives: Yes, Stanadyne Lubricity @ 2oz/tank since 1st fill-up (this is my 2nd CJAA TDI)
Problem: No warning symptoms, car shut down, "engine malfunction" (coil) light blinking. HPFP failure, metal flakes in filter and pump.
Servicing Dealer: Royal VW of Birmingham
Status: Repaired under warranty.

Car was filled with BP diesel (+ 2oz. of Stanadyne Lubricity) 145 miles earlier, the night before (have receipt.) Failed 10/19/2011, ~4:00pm. Car was completing return leg of a 120-mile daily commute when the engine malfunction light started flashing and it lost power, engine would not restart roadside. VW/dealer arranged tow (no charge) promptly, provided rental car (no charge.) Royal VW of Birmingham is diagnosing (noted metal flakes in fuel filter and pump) and is now taking a fuel sample and sending it to VWoA. VWoA repaired under warranty.

Write-up:
CUSTOMER STATES GLOW PLUG LIGHT FLASHING - ENGINE LOST POWER AND STALLED - VEHICLE TOWED IN ROADSIDE ASSISTANCE CUSTOMER STATES GLOW PLUG LIGHT FLASHING. ENGINE LOST POWER AND STALLED DTC Set P0087 FUEL RAIL SYSTEM PRESSURE TOO LOW STATIC
ENGINE NO START/RUN CONDITION REMOVED FUEL FILTER COVER HAD DEBRIS ON TOP OF FUEL FILTER CARTRIDGE ACTIVATED FUEL PUMP THROUGH BASIC SETTINGS ELECTRIC PUMP OPERATIONAL REMOVED HIGH PRESSURE PUMP SENSOR DISCOVER METALLIC DEBRIS IN ORIFICE CREATED VTA TICKET INSTRUCTED TO REPLACE ENTIRE FUEL SYSTEM REPLACED 4 INJECTOR UNITS INJECTOR FEED LINES FUEL RAIL FUEL RAIL FEED LINES REMOVED TIMING BELT REPLACED HIGH PRESSURE FUEL PUMP REINSTALLED TIMING BELT REPLACED FUEL FILTER HOUSING COMPLETE REPLACED ELECTRIC FUEL PUMP REMOVED CLEANED AND REINSTALLED FUEL FEED AND RETURN LINES REMOVED REPLACED AND REINSTALLED FUEL TANK ASSEMBLY PRIMED FUEL SYSTEM THROUGH BASIC SETTINGS MVB 35 CALIBRATED INJECTORS QUANTITY ADJUSTMENT TO IVA THROUGH GUIDED FUNCTIONS TEST DROVE VEHICLE VERIFIED SYSTEM OPERATION AT THIS TIME

Parts:
N-911-316-01 BOLT (2)
1K0-919-050-AB FUEL UNIT (1)
1K0-127-400-K FUELFILTER (1)
1K0-130-307-BJ HOSE (1)
1K0-201-293-D PIPE (1)
1K0-201-294-C PIPE (1)
5N0-130-307-J PIPE (1)
03L-201-360-G FUEL LINE (1)
1K0-130-307-BG HOSE (1)
5N0-906-129-B FUEL PUMP (1) (Lift Pump)
03L-130-089 FUEL DISTR (1)
1K0-201-060-GP TANK (1)
03L-130-755-A PUMP (1) (High Pressure Fuel Pump)
03L-130-277-A INJECTUNIT (4)
03L-130-301 PIPE (1)
03L-130-321 PIPE (1)
03L-130-301-C PIPE (1)
03L-130-301-B PIPE (1)
03L-130-235-S PIPE (1)
WHT-000-884 SEAL (4)
059-130-216-C PLATE (4)
VW1000 BOLT (1)
VW8880 BKE CLN (1)
03L-130-301-R PIPE (1)

Overall:
Less than a seven day turn-around. Car runs properly again. Diesel in tank at failure is discarded. Dealer put in 5 gallons of diesel after repair. VWoA covered all costs: towing, rental, parts and labor. VW never asked, but the car has run no biodiesel. Car purchased in Atlanta, GA, fueled only in Alabama, failure occurred in Alabama.

My to-do list:
Still working to get failed HPFP part number tag image, will get the replaced HPFP part number tag and the HPFP part number tag from my other CJAA and link them here.

I know this isn't technically a MKV, but my other TDI (same CJAA engine) is a MKV and I want this HPFP failure documented.

-speedeep

Last edited by speedeep; October 26th, 2011 at 21:43. Reason: post-repair update
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Old October 21st, 2011, 20:53   #69
RLS1400
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Join Date: Feb 2011
Location: USA
Default

Year: 2009

Build Date: 09/2008

Make/Model:
Jetta Sedan

Tranny: 6M


Mileage:
Began @ 42K, Diagnosed @ 54k, Replaced @ 57k


Diesel Fuel Source: Sunoco, Hess, Mobil

Additives: Power Service

Problem: Sudden power loss/derate, mostly at highway speeds starting around 42,000 miles. Flashing MIL/check engine light, "ENGINE FAULT WORKSHOP". Brought to dealer immediately after first incident, unable to find issue on ECU. Put up with problem until solid MIL/check engine light stayed on at 54,000 miles. Called up VWOA customer service and stated my issue, received reference number and was told to bring to dealer. Dealer able to pull faults for fuel pressure. Took a fuel sample, and received immediate approval for warranty. One month later, entire fuel system replaced under warranty @ 57,000 miles. Delayed due to backorder of parts. Loaner car provided for the 2 days it took to replace fuel system.

Dealer: Cooley VW - NY (Very impressed with their service department, extremely responsive.)

Status: RESOLVED, WARRANTY.

From repair order...

"REMOVED AND REPLACED FUEL TANK, IN TANK FUEL PUMP, TANK LINES, PLASTIC UNDERBODY FUEL LINES, RUBBER FUEL LINES TO FILTER, FUEL FILTER AND HOUSING ASSEMBLY, 2ND ASSIST FUEL PUMP, LINES TO AND FROM HIGH PRESSURE FUEL PUMP, REMOVED TIMING BELT AND REPLACED HIGH PRESSURE FUEL PUMP, INSTALLED BELT AND TIMED ENGINE TO SPEC, REPLACED STEEL LINES TO FUEL RAIL, FUEL RAIL, ALL 4 STEEL LINES TO INJECTORS, ALL 4 FUEL INJECTORS AND GASKETS, INJECTOR HOLDS, RETURN LINES AND HOSES. PROGRAMMED THE FUEL INJECTORS TO THE ECU, PRIMED AND TESTED SYSTEM. TEST DROVE VEHICLE. DRAINED AND FLUSHED SYSTEM BEFORE DISASSEBMLY. FILLED WITH NEW CLEAN FUEL. CLEARED ALL REMAINING FAULTS."

Parts...

03L130321 PIPE
03L130301 PIPE
03L130301R PIPE
03L130301B PIPE
03L130301C PIPE
03L130089 FUEL DISTR
5N0130307J PIPE
1K0127400F FUELFILTER
1K0201060GP TANK
5N0906129B FUEL PUMP
1K0919050AB FUEL UNIT
059130216C PLATE
WHT000884 SEAL
03L201360G FUEL LINE
1K0130307BJ HOSE
1K0130307BG HOSE
1K0201293D PIPE
1K0201294C PIPE
1K0130295AJ PIPE
1K0130295AH PIPE
1K0200059BH PIPE

Last edited by RLS1400; October 21st, 2011 at 20:59.
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Old October 29th, 2011, 12:23   #70
emdeeaitch
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Join Date: Dec 2004
Location: San Jose, CA
Default

Just a helpful reminder: The template for adding new cars to this thread seems to have been lost in our additional chatter (to which I contributed, sorry!). So here it is again, from the first post.

Please use the following format when posting a failure incident:

Year:
Build Date:
Make/Model:
Tranny: DSG, 6M
Mileage: (actual miles at time of problem or when problem began)
Diesel Fuel Source: (Shell, Exxon, etc.)
Additives: (Yes/No)
Problem: (HPFP failed, fuel canister rusted, etc. Give as much factual data as you can.)
Dealer: (ex. SmokeAndMirrors VW or VW of Fallacy Idaho)
Status: (still pending, dealer fixed everything, resolved, dealer refused, paid out of pocket)
__________________
2012 Golf TDI 4dr Blue Graphite DSG Sunroof & Nav
2009 Jetta TDI 6M Reflex Silver (Replacement Vehicle on 7/1/2009, sold 10/27/11), 2009 Jetta TDI 6M Reflex Silver (Lemon! Turbo failure on 5/7/2009), 2006.5 Jetta TDI Pkg1 5M 17s Reflex Silver (sold 5/6/2009), 2005 Jetta TDI GLS Leather 5M Reflex Silver (collision, sold 2006), 2003 Jetta GLI VR6 6M Platinum Grey (sold 2004), 1996 Jetta GLX VR6 5M Candy White (sold 2003)

Last edited by emdeeaitch; October 29th, 2011 at 12:26.
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Old November 8th, 2011, 07:55   #71
Kiwanda
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Join Date: Jul 2009
Location: On the prairie/forest border, just south of Canada
Default One more for the list (late 2010)

Year: 2009
Build Date: June '09
Make/Model: Jetta
Tranny: 6M
Mileage: 17,000
Diesel Fuel Source: varied, all local
Additives: none
Problem: Car started rough, died; MFD read "Engine Fault: Workshop" Would not turn over. Dealer diagnosed as HPFP failure w/associated damage to fuel system. [note: failure occurred 11/2010]
Status: Repaired under warranty, no questions asked beyond "how recently did you fill up?" Replaced fuel tank, lines, HPFP, and injectors. Dealer claimed this was the first instance they had seen of HPFP failure w/o misfueling; they had already gone through the repair procedure with "several" TDIs that had been misfueled so knew the process. They are a high volume TDI dealer and I believe trustworthy. Parts were ordered and car sat at dealer for close to three weeks before repairs were completed due to backorder of fuel pump.

*Our failure was resolved satisfactorily and at no cost. VW dealer (and VOA) were responsive, gave us a new gas Jetta to drive for three weeks, and claimed car was "good as new" when repaired. Of course, it was "good as new" when it failed the first time and they couldn't make any guarantee it would not fail again. Because we drive kids around in temps that can reach -30 at night we did not feel safe keeping the car in case it failed again away from home. We traded it about two months after the HPFP failure and no longer own a VW. We miss the driving experience and great fuel efficiency, but the HPFP worries were worth casting aside. After the trade I calculated our net cost of ownership at ~$325/month over the 18 months we owned the TDI (not including fuel), so we just pretended it was a short-term lease and moved on.
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Old November 14th, 2011, 10:47   #72
lindsaysuchy
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Join Date: Nov 2011
Location: Raleigh, NC
Default

Year: 2010
Build Date: Unknown (purchased late November 2009)
Make/Model: Jetta TDI sedan
Tranny: DSG
Mileage: ~35,650
Diesel Fuel Source: BP
Additives: No
Problem: While driving up an on-ramp to enter the interstate, the "check engine now" and glow plug lights came on. Within 10-20 seconds, the car lost all power, and I had to coast over to the shoulder of the interstate. The car would not re-start and had to be towed to the dealership. Dealer said the car was throwing "all kinds of codes." The dealer blamed "fuel contamination", not from misfueling (I have my receipt from purchasing diesel fuel the prior day), but from the poor quality of American diesel fuel. The service manager said the cars are designed to run on 100% diesel fuel and that the fuel available at gas stations in the U.S. is often not 100% pure.
Dealer: Work being performed by Leith VW of Raleigh, NC
Status: Still pending, work being performed under warranty. The parts should arrive to the dealership within the next few days, and the repair should be complete by the end of the week. This dealer quoted roughly a week from start to finish, but the sister dealership, Leith VW of Cary, claimed it's been taking an average of 4 weeks to replace all the required parts. Leith VW of Cary also said they're experiencing this problem on 4-5 cars per week at their dealership alone.

VW of America said all replaced parts come with 12-month/12,000-mile warranty. Shouldn't the entire fuel system be covered under the 60,000-mile powertrain warranty?

Has anyone had an luck being awarded a free extended warranty?

Last edited by lindsaysuchy; November 14th, 2011 at 10:52.
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Old November 22nd, 2011, 22:11   #73
53 willys
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Join Date: Aug 2008
Location: Utah
Default

Year: 2010
Build Date:
I will update this part later I forgot my build date

Make/Model: VW Sportwagen
Tranny: 6M Manual
Mileage: 47,100
Diesel Fuel Source: Conoco/Mavrick
Additives: Used B3 for about 4-5 tanks @20,000miles
Problem: I was exiting the freeway when my car lost power..the glow plug light started flashing and the service engine now light came on...car ran for maybe another 2 mins at the freeway exit light then died as I made my way to the other side of the road...I opened the fuel filter canister before I towed it to VW..I found the fuel filter to be full of metal shavings..NO RUST OR CLOUDY FUEL...JUST METAL SHAVINGS
Dealer: Strong VW of Salt Lake city, Utah
Status: Strong VW reports total fuel system failure...they are replacing the entire fuel system under the 60,000mile power train warranty...they have been very very easy and great to deal with...gave me a 2012 TDI as a loaner

its sad....I just love this car so much but now I'm worried about reliablity
__________________
~2010 SportWagen~6sp Manual~
~Votex~Black Portos~H&R Sport~Diesel Geek Skid~Stage 3/CR 170 Turbo
HPFP Failures=1st @ 47,000 miles
Stock Turbo Failure 142,000


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Old November 23rd, 2011, 06:26   #74
rich!
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Join Date: Apr 2009
Location: SoFLA
TDI(s): Touareg
Default

Year: 2011
Build Date: unsure - want to say june/july
Make/Model: JSW TDI
Tranny: DSG, 6M DSG
Mileage: (actual miles at time of problem or when problem began) ~3500
Diesel Fuel Source: (Shell, Exxon, etc.) Chevron - same station from the start.
Additives: (Yes/No) No
Problem: (HPFP failed, fuel canister rusted, etc. Give as much factual data as you can.)
Wife drove vehicle ~150 miles after 12.1 gal fill-up when accelerating in traffic on a heavy throttle the glow plug started blink + limp mode. Told her to pull over and wait a few moment and restart. TDI ran fine on her way into work and back home. We took it in, and able to reproduce blinking glow plug light on heavy throttle.

Dealer: (ex. SmokeAndMirrors VW or VW of Fallacy Idaho)
GuntherVW Coconut Creek (excellent in addressing issue and communication)

Status: (still pending, dealer fixed everything, resolved, dealer refused, paid out of pocket)

First was to drain tank as the fuel looked suspect (pink). Confirmed with Chevron this can be in fact ok. Problem still exists after flush. They tried replacing various parts in the fuel system as VW has to approve HPFP replacement. Obviously, they approved a full fuel system replacement and will complete the car in the next week or so when HPFP arrives.


Previously had an '09 with no issues
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Old November 24th, 2011, 17:38   #75
mcnzder
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Join Date: Nov 2010
Location: Cottage Grove Oregon USA
Default

Year:2010
Build Date:Not sure(where is this information)
Make/Model: Jetta
Tranny: 6M
Mileage: 34K
Diesel Fuel Source: multiple
Additives: No
Problem: 3 miles from home glow light starts blinking......not in limp mode I get home switch off wait.....take it for a quick spin no more flashing light or problem.
Next day drive 130 miles to Portland no problem. I then start out for Beaverton and the light starts blinking again turn off again starts no problem but then the light comes on again. I then take it to dealer. They take a look and replace the Tank Fuel Pump....Very good service right there and then.
I then drive it back to Portland no problem until almost at my Hotel light starts blinking and limp mode.
Next day manage to make it back to H/M they give me the rental and order in a valve or sensor not sure. Car is ready late the next day so I deffer to pick up to Sat Morning. Get less than 1 mile from H/M and the warning lights start again. Take it back.
Following Monday I get a call to order in some parts next day I get another call that they are replacing the entire Fuel system.
Dealer: Took them 3 tries but felt I received good service, in the end replace the entire fuel system
Status: Completely repaired, all under warranty, rental car paid by them for 12 days
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